Insulated concrete form apparatus and method of manufacturing the same

ABSTRACT

An insulated concrete form (ICF) is disclosed having a body. The body has a front wall and an opposing rear wall. The body includes at least one vertical passageway disposed therein that extends from the top and bottom surfaces of the body. The front, rear and side walls have an outer shell and an inner core, and the outer shell has an insert which extends from the outer shell to the inner core. A male interlock is located on the one wall and a female interlock is located on a second wall. The insulated concrete form is produced by using an insert molding process. Alternatively, the insulated concrete form may be produced by using a multiple density molding process.

CROSS-REFERENCE FOR RELATED PATENT APPLICATIONS

The present application claims the benefit of U.S. Provisional PatentApplication No. 60/711,617 filed on Aug. 26, 2005, and U.S. ProvisionalPatent Application No. 60/759,904 filed on Jan. 17, 2006, the entiretiesof which are hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates generally to construction and specificallyto insulated concrete forms that are used in the construction ofbuildings and methods of manufacturing the same.

BACKGROUND OF THE INVENTION

When constructing homes and buildings, insulated concrete forms (ICFs)comprising cavities for receiving concrete for the formation of pillarsand crossbeams are often used. ICFs are generally made of lightweightmedium density material, such as a type of foam. ICFs are typicallystacked and/or connected together for forming the desired structure.Cavities are present in the ICFs for receiving and directing the flow ofconcrete. Concrete is poured into the ICFs' cavities/passageways formingthe pillars and crossbeams that are used in constructing the building.After the concrete is poured into the cavities, the ICFs generally areleft in place in order to provide insulation to the building or home.

Existing forms of ICFs generally exhibit structural deficiencies and areprone to high rates of failure. This rate of failure often is due tomanufacturing deficiencies and/or design flaws. For example, existingdesigns may experience breakage at critical interlocks of the ICFsthereby causing leakage of the concrete when the ICF is being filled.These manufacturing deficiencies and/or design flaws can causecatastrophic failure of the ICF through separation of the ICF walls.

Furthermore, excess effort usually is required at the work site forproper installation of ICFs. ICF structures generally require use ofsteel reinforcement bars (rebar) to be placed in a critical locationwithin the pillar and/or cross beam structure. A secondary installationcomponent (e.g. a holder) is often used in order to maintain thepositioning of the steel rebar. Placement of the holder is frequentlycarried out by hand during the process of building the home or building.As each layer is built, the holder is subject to vibrations andmovement. This can cause dislocation of the holder and the rebar, whichin turn results in decreased integrity of the structure.

As mentioned above, design deficiencies in existing ICFs can causemanufacturing difficulties and structures that are not suitable for usewhen building residential and commercial structures. The production ofstructurally sound ICFs can be achieved by the use of a higher densitymaterial to form the ICF. However, higher density material in the ICFrequires more material by weight, and material costs subsequentlyincrease. Higher density material will also require longer moldingcycles for the ICF, thereby reducing productivity.

Furthermore, current designs of the interlocking structures of existingICFs also cause difficulty during the manufacturing process. Theinterlocks themselves often are damaged or broken during shipment and/orinstallation. High quantities of interlocks as well as thickness andlocation prove difficult to adequately fill with material. Additionalfilling apparatuses utilizing expensive utilities increases the cost ofproduction, which in turn, increases the costs for equipment andmaintenance.

Therefore there is a need in the field for improved ICFs that are ableto alleviate the those problems discussed above.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide an ICFthat has improved durability and/or is less susceptible to failureduring concrete filling procedures, and is further improved over currentICFs once construction is complete.

In one aspect, the invention can be an ICF having a body formed of amaterial. The body has a first wall, a second wall, and a plurality ofinner walls extending from an inner surface of the first wall to theinner surface of the second wall. The second wall is spaced from thefirst wall in a substantially parallel orientation. A plurality ofpassageways for receiving concrete are provided that extend verticallythrough the body. The passageways are separated from one another by theinner walls. A plate-like structure is disposed within one or more ofthe inner walls. The plate-like structure is constructed of a materialthat has a greater rigidity, density and/or hardness than the materialof the body.

In another aspect, the invention can be an ICF having a body formed of amaterial, the body having a plurality of passageways for receivingconcrete extending vertically through the body. The passageways areseparated from one another by inner walls. A plate-like structure isdisposed within one or more of the inner walls, the plate-like structureis constructed of a material that has a greater rigidity, density and/orhardness than the material of the body.

In yet another aspect, the invention can be an apparatus forincorporation into an ICF body. The apparatus is constructed of amaterial that provides added structural integrity. The apparatus isplate-like and has a central plate having a top edge, a bottom edge, afirst lateral edge and a second lateral edge. The first end plate isconnected to the first lateral edge of the central plate so as to beoriented substantially perpendicular to the central plate.

In still another aspect, the invention can be an ICF having a bodyhaving a first wall, a second wall, and a plurality of inner wallsextending from an inner surface of the first wall to the inner surfaceof the second wall. The second wall is spaced from the first wall in asubstantially parallel orientation. A plurality of passageways forreceiving concrete that extend vertically through the body are provided.The passageways are separated from one another by the inner walls. Thebody comprises a core portion and shell portion, the core portion isconstructed of a material having a first density and the shell portionis constructed of a material having a second density, wherein the firstdensity is greater than the second density.

In a further aspect, the invention can be a multi-density ICF. Themulti-density ICF has a body having a plurality of vertically orientedpassageways for receiving concrete. The body has a core portion andshell portion. The core portion is constructed of a material having afirst density and the shell portion is constructed of a material havinga second density, wherein the first density is greater than the seconddensity.

In a yet further aspect, the invention can be a method of manufacturingan ICF having a body having a plurality of vertically orientedpassageways for receiving concrete. The method involves the steps ofproviding a mold having an internal cavity corresponding to the body.The method further comprises the step of injecting a material having afirst density into the internal cavity of the mold in order to form acore portion of the block-like body, and leaving a portion of the cavityunfilled. The method further involves the step of injecting a materialhaving a second density into the unfilled portion of the internal cavityin order to form a shell portion about the core portion, wherein thefirst density is greater than the second density.

In a still further aspect, the invention can be a method ofmanufacturing an ICF having a body having a plurality of verticallyoriented passageways for receiving concrete. The method involves thesteps of: providing a first mold having an internal cavity; andinjecting a material having a first density into the internal cavity ofthe first mold in order to form a core portion of the body. The methodfurther involves providing a second mold having an internal cavity thatcorresponds to the body of the insulated concrete form and positioningthe core portion of the body within the internal cavity of the secondmold. The method further involves injecting a material having a seconddensity into the internal cavity of the second mold in order to form ashell portion about the core portion, wherein the first density isgreater than the second density.

In another aspect, the invention can be a method of manufacturing an ICFhaving a body having a plurality of passageways extending verticallythrough the body wherein the passageways are separated from one anotherby inner walls. The method comprises providing a mold having an internalcavity corresponding to the body; positioning a plate-like structurewithin the cavity at a location that corresponds to a location within aninner wall of the body; and injecting a material into the mold so as toencompass the plate-like structure so that the plate-like structure isdisposed within the inner wall, wherein the plate-like structure isconstructed of a material that has a greater rigidity, density and/orhardness than the injected material.

In still another aspect, the invention can be an ICF having a bodyformed of a material, the body having a first wall, a second wall, and aplurality of inner walls extending from an inner surface of the firstwall to the inner surface of the second wall, the second wall spacedfrom the first wall in a substantially parallel orientation. A pluralityof passageways are provided for receiving concrete. The passagewaysextend vertically through the body and are separated from one another bythe inner walls. A plurality of male interlocks that protrude from a topsurface of the first wall and from the bottom surface of the second wallare provided. A plurality of female depressions are located in the topsurface of the second wall and in the bottom surface of the first walls.The female depressions correspond to the male interlocks in size andshape.

These and various other advantages and features of novelty thatcharacterize the invention are pointed out with particularity in theclaims annexed hereto and forming a part hereof. However, for a betterunderstanding of the invention, its advantages, and the objects obtainedby its use, reference should be made to the drawings which form afurther part hereof, and to the accompanying descriptive matter, inwhich there is illustrated and described a preferred embodiment of theinvention

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of an ICF according to one embodimentof the present invention.

FIG. 2 is a top view of the ICF of FIG. 1.

FIG. 3 is a cut away view of the top perspective of the ICF shown inFIG. 1.

FIG. 4 is a cut away view of the top perspective of the ICF shown inFIG. 1 along the first wall illustrating the end plates of theplate-like structure of FIG. 3.

FIG. 5 is a cut away view of the top perspective of the ICF shown inFIG. 1 illustrating the placement of the plate-like structure within theinner wall.

FIG. 6 is an a perspective of a plate-like structure according to oneembodiment of the present invention.

FIG. 7 is a side view of the plate-like structure of FIG. 6.

FIG. 8 is a top view of the plate-like structure of FIG. 6.

FIG. 9 is a side view of an embodiment of a plate-like structure whenembedded in an inner wall of an ICF body according to a secondembodiment of the invention.

FIG. 10 is a side view of the ICF of FIG. 1 illustrating the plate-likestructure of FIG. 3 disposed therein.

FIG. 12 is a cross sectional view of the ICF FIG. 1 illustrating theplate-like structure disposed within an inner wall of the ICF of FIG. 1.

FIG. 13 shows an assembled concrete structure created from a stackedassembly of ICFs according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter that is regarded as theinvention, the invention will now be further described by reference tothe following detailed description of embodiments of the invention takenin conjunction with the drawings.

Referring to FIG. 1, an insulated concrete form (ICF) 100 according toone embodiment of the invention is illustrated. The ICF 100 is alightweight, insulated stay-in-place concrete form that can be used toreplace conventional concrete form work or masonry block in residentialand commercial applications. The ICF 100 comprises a body 20 that ismade of low-density expanded polystyrene (EPS), which is a type of foam.However it should be understood that other materials may be used inplace of the EPS, such as plastics, woods, fiber glass, metals andalloys. Other types of foams and materials may be used as well, such asphenolic foam, polyisocyanurate, polyisocyanurate composite, variousforms of polystyrene, and combinations thereof.

As shown in FIG. 1, the ICF 100 is comprised of a body 20 having a firstwall 21, a second wall 22, and a plurality of inner walls 29. The innerwalls 29 extend from an inner surface 32 of the first wall 21 to theinner surface 33 of the second wall 22. The second wall 22 is spacedfrom the first wall 21 in a substantially parallel orientation. Theinvention, however, is no so limited. A plurality of verticalpassageways 52 are provided for receiving and retaining concrete. Thevertical passageways 52 extend through the entirety of the body 20. Thepassageways 52 are separated from one another by inner walls 29. EachICF 100 also has end walls 35.

The standard size of the body 20 is about 48″ (1220 mm) long, about 12″(300 mm) high and about 8″ (200 mm) wide. When used, the ICF 100 willcreate about a 5″, 75% solid concrete wall. Typically the body 20 is arectangular block-like structure. Other dimensions for ICF 100 may beused depending upon the needs of the building being constructed. Oneskilled in the art will readily manufacture different dimensions asdesired.

The ICF 100 is used to make a configuration of concrete column and beamstructures in order to meet structural demands. The approximate weightof the ICF 100 is 2.7 to 2.9 pounds when using the specificationsdiscussed above. However, the weight may vary depending on thespecifications of the builder or manufacturer. In one embodiment therelatively low weight makes the ICF 100 easy to handle and maneuver.

The body 20 of the ICF 100 has a first wall 21 and a second wall 22. Thefirst and second walls 21, 22 oppose one another in a generally parallelrelation. The first and second walls 21, 22 comprise outer surfaces 23that are generally vertically planar surfaces. A plurality of verticalgrooves 24 having a generally dovetail-shaped horizontal cross-sectionalprofile are formed in outer surfaces 23 of walls 21, 22. The grooves 24extend from the top surfaces 25, 26 of the first and second walls 21, 22to bottom surfaces 27, 28 of the first and second walls 21,22. Thegrooves may be anywhere from 0.005″ to 2.0″ in width.

The grooves 24 can act as stucco retention areas. When the grooves 24are accessible from the outer surfaces 23 of the first and second walls21,22, superior adhesion of concrete or stucco to the ICF 100 can beachieved. The grooves 24 are located on both the first and second walls21, 22 in order that flexibility in positioning of the ICF blocks 100can be maintained while retaining the ability to provide improved stuccoretention areas. In alternative embodiments, dovetail cross-sectionalprofiles for the grooves 24 do not have to be used. Instead, othercross-sectional profiles can be used, such as a T Slot, L shaped and/orV groove design. Furthermore, it is possible to have these alternativeprofiles used in conjunction with the dovetail cross-sectional profile.

Still referring to FIG. 1, the ICF 100 comprises an interlock systemthat comprises a plurality of male protrusions 41 extending from the topsurface 26 of the second wall 22 and a plurality of corresponding femaledepressions 31 located on top surface 25 of the first wall 21. Theinterlock system provides improved stability when stacking the ICFs. Asshown in FIGS. 9-12, a set of male protrusions 41 also extend from thebottom surface 27 of the first wall 21 while a corresponding set offemale depressions 31 also exist in the bottom surface 28 of the secondwall 22. The male protrusions 41 are sized and shaped so as to beslidably insertable into the corresponding female depressions 31 onanother ICF 100.

Referring back to FIG. 1, the male protrusions 41 are designed asslightly angled ridges that correspond to the slightly angled femaledepression 31 in order to form a tight fit. The male protrusion 41 maytake the form of a variety of shapes so long as the female depression 31takes on the corresponding depression shape. When the male protrusions41 and the female depressions 31 are arranged on the surfaces 25-28 ofthe first and second walls 21, 22 of a number of the ICFs 100, a matingengagement occurs that is used to stack the ICFs 100 in slidingengagement.

In one embodiment, the surfaces 26, 27 which contain the maleprotrusions 41 are free of the female depressions 31 and the surfaces25, 28 which contain the female depressions 31 are free of the maleprotrusions 41. This allows mating engagement of the stacked ICFs 100 tooccur without being concerned as to which surface of the ICF 100 ispositioned as the top or the bottom. In other words, the orientation ofthe ICF 100 will not matter. It should be understood that it is possibleto have both the male protrusions 41 and the female depressions 31alternate on each of the surfaces 25-28. This is accomplished by having,for example, a male protrusion 41 placed on a first top surface followedby a female depression 31 and subsequently followed by a male protrusion41. On the opposing second top surface there would be a femaledepression 31 followed by a male protrusion 41 followed by a femaledepression 31. This sequence would be repeated on the opposite bottomsurfaces of the ICF 100. In this way the flexibility of positioningwould still be maintained as well as the interlock capability.

As shown in FIGS. 1-5, the body 20 of ICF 100 further comprises aplurality of inner walls 29 that extend between and connect the innersurfaces of first and second walls 21, 22. Inner walls 29 are spacedfrom one another and form vertical passages 52 there between as shown inFIGS. 1-5. As shown in more detail in FIG. 3, inner walls 29 have angledtop and bottom surfaces 43 that cooperate with planar walls 44 in orderto facilitate the flow of concrete into vertical passages 52. The slopesand angles of top and bottom surfaces 43 of inner walls 29 may bealtered in order to provide different shapes and forms to the resultingconcrete structures.

Still referring to FIGS. 1-5, In addition to assisting in the formationof vertical passage 52, inner walls 29 additionally assist in theformation of top channel 49 and bottom channel 47. Placed within theserespective channels are reinforcing bars commonly known as rebar andheld in place by plate-like structure 40, which is discussed in greaterdetail below. The reinforcing bars are typically solid cylindrical metalbars, approximately ½″-¾″ in diameter and made in varying lengths. Topchannel 49 and bottom channel 47, as shown, form an octagonal shape whenICF 100 is mated with a corresponding ICF 100. The channels may take onvarious other shapes depending on the desired shaped of the finishedproduct.

As shown in FIGS. 1-5, the ICF 100 further comprises a plurality ofplate-like structures 40 disposed within the interior of the inner walls29. FIG. 5 in particular illustrates how a plate-like structure 40 isplaced within an inner wall 29. As shown in FIGS. 1-5, the edge 17 ofplate-like structure 40 has a series of semi-circular indentations 12.When rebar is placed within the top channel 49 and the bottom channel 47it is positioned within the indentations 12.

Now turning to FIGS. 6-8, where a more detailed view of the plate-likestructure 40 is shown, the plate-like structures 40 are constructed of amaterial, such as high density EPS, that typically has a higher densitythan body 20. However it is possible to construct the plate-likestructure 40 out of a material that has a greater rigidity, densityand/or hardness, or a combination thereof. The plate-like structure 40can function as a rigid substructure that withstands the pressureexerted during the concrete fill. The plate-like structure 40 mayfurther provide a high tensile strength that improves the structuralportion of the ICF 100.

Still referring to FIGS. 6-8, each plate-like structure 40 comprises atleast one semi-circular indentation 12 formed in the edge 17. The edge17 may be made of molded plastic, or another material suitable forproviding support and reinforcement for the ICF 100 and rebar. Theindentations 12 are formed on each end of the plate-like structure 40and are designed to receive and hold rebar in place. The semi-circularindentations 12 are preferably aligned along the axes of the ICF 100.

Three indentations 12 are shown formed in each edge 17 shown in FIGS.6-8. More or less indentations 12 may be formed, space permitting.Additionally, the shape of the indentation 12 is not limited to beingsemi-circular but may be shaped to correspond to the structure of therebar that is going to placed within the ICF 100. Although semi-circularmay be used it is envisioned that half-rectangular, half-square,half-hexagonal, half-octagonal, or any other various polygonal shape maybe used. The indentations 12 are designed to provide accuratearrangement for the rebar in order to insure accurate positioning insideupper channel 49 and lower channel 47 when concrete is poured through.This arrangement provides improved tensile strength due to thecross-sectional area as well as facilitating placement of rebar duringthe construction process.

FIG. 9 shows an embodiment of a plate-like structure 40 situated withinan inner wall 29 wherein only one semi-circular indentation 12 isformed. In the embodiment shown in FIG. 9, the semi-circular indentation12 is arranged so as to be centrally located within the interlockedupper channel 49 and the lower channel 47.

Returning to FIGS. 6-8, running perpendicular to edges 17 and centralpiece 18 are the planar surfaces that form the end plates 30. The endplate 30 runs parallel to the vertical length of the inner wall 29. Inthe embodiment shown in FIGS. 6-8, more than one end plate 30 isattached to the plate-like structure 40. It should be understood that itis possible to use only one end plate 30. Furthermore, the end plate 30may be shaped in a different manner from that which is shown, such asbeing sloped and/or angled with respect to the vertical length of theinner wall 29.

The end plates 30 of the plate-like structure 40 shown in FIGS. 6-8 areplaced within first and second walls 21, 22 in order to provide astructure in which screws used to hold other materials to the ICF 100,such as dry wall, can be secured and to further provide additionalanchoring for plate-like structure 40. This can be seen in detail inFIGS. 2, 4, and 5. In the embodiment shown, the end plate 30 may belocated relatively proximate to groove 24. FIG. 4 illustrates theplacement of end plate 30 within the sidewall 22. The end plates 30 maybe made of a variety of materials such as plastic, foam, metal, alloys,wood or whatever material is used in the construction of the plate-likestructure 40.

Preferably the end plates 30 are accessible regardless of which of thefirst or second wall 21, 22 is facing the exterior. It is possible thatthe end plates 30 are placed within only one of the walls. Inembodiments where there is only one end plate 30 the wall having the endplates 30 embedded within should be the wall that is accessible for usein hanging materials. The end plates 30 are shown as being unitarilyformed, however it is possible that the end plates 30 be formed as aseries of structures attached to plate-like structure 40 and are notlimited to being a planar surface.

Referring to FIGS. 6-8, the edges 17 have circular holes 16 formed atvarious locations. These may be the result of the production processused in making the plate-like structures 40. These holes 16 may also belocated on the central piece 18 of the plate-like structure 40. Theholes 16 may also assist in providing structural integrity to theplate-like structure 40 while also reducing the overall amount ofmaterial needed in order to form the plate-like structure 40. Thecentral piece 18 also can provide structural reinforcement for the firstand second walls 21, 22 by becoming an integral part of the finishedcomposite. The central piece 18 may also be able to retain sufficientstrength while reducing material expenditure. This can reduce overallcosts.

Now turning to FIG. 10, a side view of the inner wall 29 illustratingthe plate-like structure 40 placed within is shown. The edges 17 extendabove and below a top and bottom surface of the inner wall 29. The topand bottom surface of inner wall 29 is generally shaped in order tocorrespond to the shape and size of the upper channel 49 and the lowerchannel 47. The semi-circular indentations 12 are shown positioned atthe location that would correspond to the centers of the upper channel49 and the lower channel 47 when two ICFs 100 are joined together in aninterlocking position. During construction of a building, concrete ispoured into these channels and will eventually solidify around the rebarplaced within the indentations 12.

FIG. 11 illustrates the placement of the plate-like structure 40 withinthe first wall 21 and the second wall 22. As discussed above, the endplate 30 is embedded into the first and second walls 21, 22 as well asbeing integrally placed within the inner wall 29. The placement of theplate-like structure 40 within both the inner wall 29 and the first andsecond walls 21, 22 operates to provide additional reinforcement andstructural integrity.

FIG. 12 illustrates the interior of the vertical passage 52, which isformed by the surfaces of two opposing inner walls 29. The planar walls44 are provided within the vertical passage 52 and formed from the innerwalls 29. The top and bottom surfaces 43 are also formed from the innerwall 29. The top and bottom surfaces 43 are sloped in order tofacilitate the flow of concrete into the vertical passages 52. Duringthe pouring of concrete mix into the ICFs 100 the shape and positioningof the various slopes that help form the vertical passage 52 as well asthe upper channel 49 and the lower channel 47 provide improved flow andbetter mold shape for when the concrete mix solidifies.

FIG. 13 illustrates what the solidified concrete structure 60 is shapedlike after being placed with a fully interlocked assembly of the ICFs100. Not shown is the surrounding material from the ICF 100, which asdiscussed in more detail below would preferably be a material, such asfoam, that would have a relatively high R value. As discussed below thesurrounding ICF material provides insulation and additional structuralintegrity to the building constructed with it.

Now turning to the manufacturing and construction of the ICF 100. TheICF 100 may be constructed so that the body 20 comprises a core portionand shell portion. This is part of the multi-density manufacturingprocess and may be used in both the total mold manufacturing process andthe insert manufacturing process. The core portion is preferablyconstructed of a material having a first density and the shell portionis preferably constructed of a material having a second density. Thefirst density is greater than the second density. The shell portion andthe core portion may be constructed with the materials disclosed abovewith respect to forming the body 20. The shell portion is composedprimarily of that portion of the ICF 100 that forms body 20, as well asouter surface 23 and the first and second walls 21, 22. While the coreportion is typically composed of those portions of the ICF 100 that issurrounded by the shell portion and may include the interior of thewalls, although it is possible to have some portions of the corematerial not be surrounded by the shell material, for example when thecore portion comprises the inner walls 29. The size of the core and theshell may varying depending upon the needs of the projects.

During manufacture of the ICF 100 the usage of the plate-like structure40 allows the body 20 to be molded into a block form with a material forthe shell that has a density that is lower than what is commonly used.By using a material with a lower density a higher R-value may beachieved. A material's R-value is the measure of its resistance to heatflow. The higher the R-value, the more the material insulates. Thus, anoptimum R-value density material may be used for the body 20. Thisresults in energy saving for cooling and heating.

It is possible to have the plate-like structures 40 formed integral tothe body 20 via a molding process. Alternatively, integral insertmolding may also be used to produce the ICF 100. The integral insertmolding process is accomplished by using a mold designed to allow theplate-like structures 40 to be set in the mold prior to being filledwith lower density material. The mold is designed to allow material toflow around and encapsulate portions of the plastic or metal insert.

In the integral insert molding process an internal cavity correspondingto the body 20 may be provided. The plate-like structure 40 ispositioned within the internal cavity at a location that corresponds toa location that would be within one of the inner walls 29 that is withinthe body 20. A material is then injected into the mold so as toencompass the plate-like structure 40 so that the plate-like structure40 is then disposed within the inner wall 29. When using this process itis intended that the plate-like structure 40 is constructed of amaterial that has a greater rigidity, density and/or hardness than thematerial that is used to form the remainder of the body 20.

When using the multiple density molding in conjunction with integralinsert molding, higher density EPS, or another foam material, may bemolded into the ICF where required. This further assists in preventingform failure. It also allows for lower density material to fill theremainder of the block form, thereby providing higher insulation valueof the block form by providing a higher R value.

Two alternative embodiments of the ICF 100 are end blocks and cornerblocks. End blocks are formed much in the same way that ICF 100 isformed, however in order to permit it to be placed at specific locationswithin a building at least one end of the ICF 100 must have an end wall35 that is flush with the top surfaces 25, 26 and bottom surfaces 27, 28of the ICF 100. By having one end wall 35 flush with the surfaces, upperchannel 49 and lower channel 47 are blocked.

The corner block is also constructed so as to be positioned indesignated locations within a building. In making the corner block anend block is molded by means of a changeable tooling insert within amold. The corner block is designed to be used for either the right handor left hand corner or alternatively as a T or pilaster section in afinished wall section. A method used for manufacturing the corner blockis that of a heated bent wire in the form of the shape of the materialmatching that of the cavity formed within the horizontal length sectionof the top and bottom of the block. A corner block takes an end blockand places a channel within an outer surface 23.

The heated bent wire fixture has two wires which form the top and bottomcore of the block. This fixture is made to allow insertion of the cornerblock in a fixed position that is proper for the bent wires. A leverworking within this fixture releases and moves by means of a springmechanism and dampening device the bent wires at a fixed rate of speedfor proper melting of the EPS material which makes up the block. Thefixture also allows for the corner block to be inverted thereby allowingthe corner block to become a right or left hand corner block.

It is to be understood, however, that even though numerouscharacteristics and advantages of the present invention have been setforth in the foregoing description, together with details of thestructure and function of the invention, the disclosure is illustrativeonly, and changes may be made in detail, especially in matters of shape,size and arrangement of parts within the principles of the invention tothe full extent indicated by the broad general meaning of the terms inwhich the appended claims are expressed

1. An insulated concrete form comprising: a body formed of a material,the body having a first wall, a second wall, and a plurality of innerwalls extending from an inner surface of the first wall to the innersurface of the second wall, the second wall spaced from the first wallin a substantially parallel orientation; a plurality of passageways forreceiving concrete extending vertically through the body, thepassageways separated from one another by the inner walls; and aplate-like structure disposed within one or more of the inner walls, theplate-like structure constructed of a material that has a greaterrigidity, density and/or hardness than the material of the body.
 2. Theinsulated concrete form of claim 1 wherein the plate-like structure isdisposed within the one or more inner walls in a substantially verticalorientation.
 3. The insulated concrete form of claim 2 wherein theplate-like structure is disposed within the one or more inner walls sothat a portion of the plate-like structure protrudes from a top surfaceof the inner wall and a portion of the plate-like structure protrudesfrom the bottom surface of the inner wall; and wherein the plate-likestructure comprises one or more indentations in a top edge of theplate-like structure for receiving rebar and one or more indentations ina bottom edge of the plate-like structure for receiving rebar.
 4. Theinsulated concrete form of claim 3 wherein the one or more indentationsare semi-circular in shape.
 5. The insulated concrete form of claim 1further comprising: a first channel extending the length of the bodybetween the first and second walls, the first channel being located atthe top of the body and above the inner walls; a second channelextending the length of the body between the first and second walls, thesecond channel being located at the bottom of the body and below theinner walls; wherein the plate-like structure is disposed within the oneor more inner walls in a substantially vertical orientation so that aportion of the plate-like structure protrudes from a top surface of theinner wall into the first channel and a portion of the plate-likestructure protrudes from the bottom surface of the inner wall into thesecond channel; and wherein when two of the insulated concrete forms arearranged in a stacked assembly, the first channel of one of theinsulated concrete forms is in spatial communication with the secondchannel of the other of the insulated concrete forms so as to form asubstantially horizontal passageway for receiving concrete.
 6. Theinsulated concrete form of claim 1 wherein one of the plate-likestructures is disposed within each inner wall of the body.
 7. Theinsulated concrete form of claim 1 wherein one of the plate-likestructures is disposed within every second or third of the inner wallsof the body.
 8. The insulated concrete form of claim 1 wherein theplate-like structure comprises a central plate, a first end plate and asecond end plate, the first and second end plates connected to opposinglateral edges of the central plate so as to be substantially parallel toone another and substantially perpendicular to the central plate,wherein the central plate is disposed within the inner wall of the bodyand the first and second end plates are disposed within the first andsecond walls of the body respectively.
 9. The insulated concrete form ofclaim 8 wherein the first and second end plates have a major planarsurface, the major planar surfaces of the first and second end platesbeing substantially parallel to the outer surfaces of the first andsecond walls respectively.
 10. The insulated concrete form of claim 1further comprising: a first channel extending the length of the bodybetween the first and second walls, the first channel being located atthe top of the body and above the inner walls; and a second channelextending the length of the body between the first and second walls, thesecond channel being located at the bottom of the body and below theinner walls.
 11. The insulated concrete form of claim 10 wherein whentwo of the insulated concrete forms are arranged in a stacked assembly,the first channel of one of the insulated concrete forms is in spatialcommunication with the second channel of the other one of the insulatedconcrete forms so as to form a substantially horizontal passageway forreceiving concrete.
 12. The insulated concrete form of claim 1 whereinthe body comprises a core portion and a shell portion, the core portionconstructed of a foam having a first density and the shell constructedof a foam having a second density, wherein the first density is greaterthan the second density.
 13. The insulated concrete form of claim 12wherein the body is formed of a foam material.
 14. The insulatedconcrete from of claim 1 further comprising a plurality of maleinterlocks protruding from a top surface of the first wall and aplurality of female depressions located in the top surface of the secondwall, the female depressions corresponding to the male interlocks insize and shape.
 15. The insulated concrete form of claim 14 wherein thetop surface of the first wall is free of female depressions and the topsurface of the second wall is free of protruding male interlocks. 16.The insulated concrete form of claim 14 further comprising: a pluralityof the male interlocks protruding from the bottom surface of the secondwall and a plurality of the female depressions located in the bottomsurface of the first wall; and wherein when two of the insulatedconcrete forms are arranged in a stacked assembly: (i) the maleinterlocks on the top surface of the first wall of one of the insulatedconcrete forms slidably mates with the female depressions on the bottomsurface of the first wall of the other of the insulated concrete forms;and (ii) the male interlocks on the bottom surface of the second wall ofthe other of the insulated concrete forms slidably mates with the femaledepressions on the top surface of the second wall of the one of theinsulated concrete forms.
 17. The insulated concrete form of claim 1further comprising one or more grooves in an outer surface of the firstand second walls.
 18. The insulated concrete form of claim 17 whereinthe groove has a cross-sectional profile that is a dove-tail shape, asubstantially L shape, or a substantially T-shape.
 19. The insulatedconcrete form of claim 1 further comprising a first end wall and asecond end wall, the first end wall connecting the first and secondwalls at a first end of the body and the second end wall connecting thefirst and second walls at a second end of the body.
 20. The insulatedconcrete form of claim 1 further comprising: a first channel extendingthe length of the body between the first and second walls, the firstchannel being located at the top of the body and above the inner walls;a second channel extending the length of the body between the first andsecond walls, the second channel being located at the bottom of the bodyand below the inner walls; wherein the plate-like structure comprises acentral plate, a first end plate and a second end plate, the first andsecond end plates connected to opposing lateral edges of the centralplate, wherein the central plate is disposed within the inner wall in asubstantially vertical orientation and the first and second end platesare disposed within the first and second walls of the body respectively;and wherein a top portion of the central plate of the plate-likestructure protrudes from a top surface of the inner wall into the firstchannel and a bottom portion of the central plate of the plate-likestructure protrudes from the bottom surface of the inner wall into thesecond channel.
 21. The insulted concrete form of claim 1 wherein thebody is constructed of an expanded polystyrene and the plate-like insertis constructed of a plastic, a metal, an alloy or a combination thereof.22. The insulated concrete form of claim 1 wherein the plate-likestructure comprises a plurality of cutouts, the material of the bodypassing through the cutouts.
 23. An insulated concrete form comprising:a body formed of a material, the body having a plurality of passagewaysfor receiving concrete extending vertically through the body, thepassageways separated from one another by inner walls; and a plate-likestructure disposed within one or more of the inner walls, the plate-likestructure constructed of a material that has a greater rigidity, densityand/or hardness than the material of the body.
 24. An apparatus forincorporation into an insulated concrete form constructed of a materialto provide added structural integrity, the plate-like apparatuscomprising: a central plate having a top edge, a bottom edge, a firstlateral edge and a second lateral edge; and a first end plate connectedto the first lateral edge of the central plate so as to be orientedsubstantially perpendicular to the central plate.
 38. An insulatedconcrete form comprising: a body having a first wall, a second wall, anda plurality of inner walls extending from an inner surface of the firstwall to the inner surface of the second wall, the second wall spacedfrom the first wall in a substantially parallel orientation; a pluralityof passageways for receiving concrete extending vertically through thebody, the passageways separated from one another by the inner walls; andwherein the body comprises a core portion and shell portion, the coreportion constructed of a material having a first density and the shellconstructed of a material having a second density, wherein the firstdensity is greater than the second density.